Auxiliary power system for trucks and other heavy duty vehicles

ABSTRACT

An auxiliary power system for a truck or other heavy duty vehicle. A secondary engine which is smaller than the vehicle&#39;s main engine is used to generate heat and electrical power, and to drive an auxiliary air conditioning system. The coolant systems of the two engines are interconnected so that when the main engine is off and the secondary engine is on, waste heat from the secondary engine is transferred by coolant flowing through the water jacket of the secondary engine to the main engine and also to heater cores in the truck&#39;s cab and sleeper. An electrical generator driven by the secondary engine provides electrical energy. The auxiliary air conditioning system includes an auxiliary compressor and an auxiliary condenser, and connections for efficiently interconnecting the auxiliary air conditioning system with the truck&#39;s primary air conditioning system. The auxiliary power system permits the use of a small and efficient engine to keep the truck&#39;s main engine and cab warm and to run a variety of other accessories without having to run the truck&#39;s main engine.

The present invention relates generally to a auxiliary power system foruse in trucks and other heavy duty vehicles, and particularly to acogeneration system which can provide heat to a primary engine forfacilitating restarting the primary engine in cold weather, as well asauxiliary electrical power and air conditioning.

BACKGROUND OF THE INVENTION

The problem addressed by the present invention is that, during thewinter, cross country truckers traditionally idle their engines duringovernight rest stops to assure cold weather restart and to provide heatin the cab. In particular, to enable cold weather restart it isimportant to keep the truck's motor oil and diesel fuel warm. As is wellknown, motor oil provides proper engine lubrication only within alimited temperature range, and diesel fuel typically begins to wax attemperatures below 40 degrees Fahrenheit and becomes a virtuallyunusable gel at temperatures below 20 degrees Fahrenheit.

Idling the main truck engine overnight is one way to keep the truck'smotor oil and diesel fuel warm and to thereby assure cold weatherrestart. This use of the main truck engine, however, is veryinefficient. Typical truck engines, such as 300 to 500 BHP Dieselengines, are very inefficient when operated at 600 to 900 RPM at only 10to 20 BHP--i.e., the power level needed to idle the engine and to drivethe truck's electrical generator, cab heater or air conditioner, andother cab accessories.

As provided by the present invention, one solution to the problem ofmaintaining a habitable environment in a truck cab overnight and keepingthe engine warm so that it can be restarted after a cold winter's night,is to use a small cogeneration system which can perform these functionsmore efficiently than the truck's main engine. In particular, thecogeneration system includes a supplemental engine which supplies heatto certain engine components and also supplies power to a selected setof cab accessories which are normally powered by the main engine.Furthermore, the supplemental engine of the present invention can andpreferably does use the same fuel supply as is used for the main truckengine.

The prior art includes a number of supplementary engine systems, oftencalled pony engines, for use in trucks. See, for example, U.S. Pat. Nos.4,682,649 (Greer, 1987) and 4,448,157 (Eckstein et al., 1984). However,the prior art pony engines have, generally, been too complicated,expensive and insufficiently energy efficient to achieve significantcommercial success.

The present invention provides improved energy efficiency and reducedcomplexity by interconnecting the fluid coolant systems of the truck'sprimary and auxiliary engines, and using this interconnection as thesole mechanism for providing heat to the primary engine and the truck'scab and sleeper heaters.

The present invention also provides improved auxiliary air conditioningby providing an auxiliary condenser as well as an auxiliary compressor,and electrical controls for selectively enabling either the auxiliary orthe primary compressor. The electrical control allow the auxiliaryengine to drive the auxiliary compressor even when the primary engine isrunning, thereby allowing the air conditioning load to be removed fromthe primary engine.

It is therefore a primary object of the present invention to provide animproved auxiliary power system for trucks and other heavy dutyvehicles.

Another object of the present invention is to provide a truckcogeneration system that uses waste heat from an auxiliary engine toheat the truck's main engine, cab and sleeper compartment.

SUMMARY OF THE INVENTION

In summary, the present invention is an auxiliary power system for atruck or other heavy duty vehicle. The auxiliary system uses a secondaryengine which is smaller than the vehicle's main or primary engine andwhich is more efficient than the vehicle's main engine at low energyoutput levels.

The auxiliary engine includes a water jacket which is interconnectedwith the main engine's coolant system. Coolant fluid flows through theauxiliary engine's water jacket, drawing heat from the auxiliary engine.The coolant then flows through the main engine's water jacket, therebyheating the main engine block. The coolant fluid heated by the auxiliaryengine is also used for heating the truck's cab and sleeper compartmentswhen the main engine is not in use. The use of this auxiliary powersystem permits the use of a small and efficient engine to keep thetruck's motor oil, fuel and cab warm and to power a variety of cabaccessories without having to run the vehicle's primary engine.

In the preferred embodiment, the auxiliary engine also drives anauxiliary alternator which charges the truck's batteries and provides110 volt a.c. power to the truck's sleeper compartment.

BRIEF DESCRIPTION OF THE DRAWINGS

Additional objects and features of the invention will be more readilyapparent from the following detailed description and appended claimswhen taken in conjunction with the drawings, in which:

FIG. 1 is a schematic drawing of a cogeneration system in accordancewith the invention.

FIG. 2 depicts the electrical controls for the main and auxiliary airconditioning compressors in the preferred embodiment.

DESCRIPTION OF THE PREFERRED EMBODIMENT

FIG. 1 shows the primary components of an auxiliary power system forproviding heating, air conditioning and electrical power to the cab 22,and sleeper 24 of a truck 20. An auxiliary engine 30 is coupled to thetruck's cooling, air conditioning and electrical systems which are alsocoupled to the truck's main or primary engine 26. This auxiliary engine30 is substantially smaller than and independent of the main engine 26,and is used to provide power to selected preexisting accessories whenthe main engine 26 is not in use. In the preferred embodiment theauxiliary engine is a diesel 10 BHP engine such as the Model ZB600engine made by Kubota. More generally, auxiliary engines will generallybe diesel fuel engines with capacities between 5 and 25 BHP.

For the purposes of this specification, the term "truck" is defined toinclude any heavy duty vehicle.

Primary Engine And Associated Equipment

In the preferred embodiment, before the addition of the auxiliary powersystem, the truck is already equipped with the following components. Asis standard, the truck's engine cooling system includes a radiator 32 influid connection with the jacket of the main engine 26, and a coolingfan 34. The main engine includes a control valve (not shown) thatenables the flow of coolant fluid from the main engine jacket throughthe radiator 32 only when a thermostat indicates that the main engine'stemperature exceeds a specified temperature. A water pump 35 providesthe line pressure required to ensure adequate circulation of coolantfluid through the main engine's jacket and the radiator 32.

The cab 22 and the sleeper 24 in the truck each have heating units(i.e., heater cores) 36 and 37, and air conditioning units 38 and 39. Arefrigerant (i.e., freon 12, also known as R12) compressor 40 driven bythe main engine 26 provides high pressure freon to the air conditioningunits 38 and 39. Compressed freon flows from this compressor 40 to acondenser 42, and then to a receiver 44. In the preferred embodiment thereceiver 44 is a freon dryer having a T-connection at its outlet so thatfreon is supplied by the receiver 44 to both the cab and sleepers aircondition units 38 and 39.

Solenoid valves 46 and 48 are used to control the flow of freon into theair conditioning units 38 and 39 in the cab 22 and sleeper 24,respectively. Similarly, there are separate expansion valves 50 and 52at the inlets to the cab and sleeper air conditioning units. Standard,independent controls are used to open the solenoid valves 46 and 48 inaccordance with selection made by the system's user.

As is standard in trucks and other vehicles, a flow control valve 54controls the flow of heated coolant fluid through the heater cores 36and 37 in the cab and sleeper. The amount of flow through valve 54 iscontrolled by a heat level selection lever 56 in the cab 22.

In the preferred embodiment there is also an electrically powered fuelheater 58 surrounding the main engine's fuel filter (not shown) forliquifying gelled diesel fuel in cold weather. For trucks used inextremely cold climates a second electrically powered fuel heater isadded to the fuel filter for the auxiliary engine 30. In an alternateembodiment, a fuel heater could be provided for directly heating thefuel tank 62.

It should be noted that a single cooling fan 34 is used to cool both themain engine radiator 32 and the condenser 42. This fan 34 is controlledusing a temperature sensor on the output line of the radiator 32, apressure sensor on the outlet of the freon dryer 44, and an manualoverride switch in the cab 22. The fan 32 is automatically turned onunder any one of three conditions: (1) if the main engine is on and thetemperature of the main engine's coolant fluid exceeds a specifiedtemperature, (2) if the pressure in the on the outlet of the freon dryer44 exceeds a specified pressure level, or (3) if a manual overrideswitch is closed (i.e., turned on) by the driver in the truck's cab 22.

Auxiliary System

As discussed above, the main purpose of the auxiliary engine 30 is toallow the use of a smaller and more efficient engine to heat selectedsystem components and to drive selected accessories when the main engineis not in use. These selected components and accessories typicallyinclude electrical accessories such as lights and fans, components whichuse thermal energy such as the cab and sleeper heaters 36 and 37, andaccessories which use mechanical power such as an auxiliary freoncompressor 66.

The auxiliary engine 30 also acts as a cogeneration system in that wasteheat from the auxiliary engine 30 is used to perform useful work--i.e.,providing heat to the main engine 26, the cab 22 and the sleeper 24.Furthermore, both the main and secondary engines share the same fuelsupply 62.

In the preferred embodiment, the auxiliary power system 30 is mounted ina modified version of the truck's tool box, which is mounted on thetruck's frame rail.

Electrical Generator

The auxiliary engine's crank shaft 70 drives an auxiliary electricalgenerator 72 (i.e., an alternator). In the preferred embodiment, thealternator 72 (e.g., the model 4.5KVA MARK3 alternator made by USEnergy) generates both 12 volts d.c., and 110 volts a.c. The 12 voltd.c. output from the generator recharges the truck's 12 volt battery 74,and the 110 volt a.c. output is coupled to one or more outlets 76 in thesleeper 24 so that standard 110 volt accessories can be used in thesleeper.

Coolant Fluid System

The auxiliary engine 30 uses the same coolant fluid as is used by themain engine 26. Thus the same coolant fluid passes through the jacketsof both engines and, when the auxiliary engine is used, heat from theauxiliary engine 30 is transferred to main engine 26, therebymaintaining the main engine block at a temperature which facilitateseasy starting. Conversely, coolant will flow through the auxiliaryengine's jacket when the main engine 26 is running but the auxiliaryengine 30 is off.

It should be noted that in the preferred embodiment the oil in the mainengine's crankcase is heated (so as to maintain a proper oil viscosityfor starting the main engine 26) solely by the flow of hot coolant fluidthrough the main engine's jacket.

The truck's coolant plumbing system, and the direction of flow ofcoolant through the plumbing system, is identified by solid arrows drawnnext to the lines which carry coolant.

In the preferred embodiment, a hot exhaust heat exchanger is not used toheat the truck's coolant fluid because such heat exchangerssignificantly increase the cost, complexity and maintenance costs of theauxiliary power system. All cogeneration heat is provided directly bycoolant fluid flowing through the auxiliary engine's jacket. Hot exhaustfrom the auxiliary engine is expelled through exhaust line 80 andmuffler 82, which are separate from the exhaust line and muffler for themain engine.

The primary flow path of coolant fluid, when the auxiliary engine 30 isturned on, is as follows. Coolant fluid in the auxiliary engine's jacketis pumped into line 90 by an auxiliary water pump 92 that operates onlywhen the auxiliary engine is on. The auxiliary water pump 92 providesthe line pressure required to keep the coolant flowing through theentire coolant plumbing system when the main engine is off and only theauxiliary engine is running. Water pump 92 may be built into theauxiliary engine 30 or it may be driven by belt or other mechanicalmeans coupled to the auxiliary engine's drive shaft 70.

From line 90, coolant flows through a one way check valve 94 into aT-valve 96 and then into the water jacket 98 of the main engine 26.Coolant leaves the main engine's water jacket 98 at outlet 100, flowinginto plumbing lines 102 and 104. Line 102 directs coolant fluid to theheat cores 36 and 37, and thus coolant flows through this line only tothe extent that heating control valve 54 is open. Coolant returning fromthe heater cores flows through line 106, one way check valve 10 and thenthrough T-valve 96 back to the main engine's water jacket 98.

Coolant fluid line 104 directs coolant exiting the main engine's jacketinto the auxiliary engine's water jacket 110. As explained above, thecoolant exits the auxiliary engine's water jacket through the auxiliarywater pump 92.

Check valves 94 and 108 prevent coolant fluid leaving the auxiliaryengine from flowing toward the heater cores 36 and 37 in opposition tothe normal flow of coolant through the plumbing system. Furthermore,when the main engine is on and the auxiliary engine is off, these checkvalves ensure that while coolant flows through the auxiliary engine'swater jacket 110 (thereby enabling easy starting of the auxiliary enginein cold weather and also helping to dissipate waste heat generated bythe main engine), the auxiliary system does not interfere with thenormal flow of coolant through the plumbing system.

As noted above, coolant in the main engine's water jacket 98 will flowthrough radiator 32 only when a thermostat in the main engine opens avalve between the main engine's water jacket 98 and the radiator 32.This valve will open at the thermostat's set point even if the mainengine is off. The inventors have found that even though the radiatorcooling fan 34 and the main engine's water pump 35 are not turned onwhen the main engine is off, the radiator 32 will dissipate enough heatwhen only the auxiliary engine 30 is running to maintain the coolantfluid at an acceptable temperature.

In an alternate embodiment, excessive heating of the coolant fluid couldbe further prevented by providing a small, auxiliary radiator betweenthe auxiliary water pump 92 and check valve 94, along with an electricfan for cooling the auxiliary radiator. In yet another alternateembodiment, a safety switch could be provided in the auxiliary enginewhich would turn off the auxiliary engine in the event that the coolanttemperature exceeded a preset limit.

Auxiliarv Air Conditioning

The auxiliary engine 30 drives an auxiliary freon compressor 120 so thatair conditioning can be provided to the cab and sleeper when the mainengine 26 is off. The auxiliary compressor 120 is driven by theauxiliary engine's drive shaft 70. As is standard in many vehicularcompressors, the compressor's drive shaft is coupled to the compressordrive belt by a magnetic clutch (not shown) so that the compressor 120can be turned on and off.

Note that the terms refrigerant and freon are used interchangeably inthis specification. As will be understood by those skilled in the art,the freon and associated components used in the preferred embodimentcould be replaced with another refrigerant and corresponding componentsin alternate embodiments of the present invention.

The electrical control for the main and auxiliary compressors is shownin FIG. 2. The truck's normal on/off and air conditioning thermostaticswitches 122, 124, 126 and 128 and solenoid valves 46 and 48 areretained. However, a relay 130 is added for switching between the mainand auxiliary compressors 40 and 120. When the auxiliary engine 30 ison, main/aux switch 132 is closed, thereby enabling the auxiliarycompressor 120 to be energized; when the auxiliary engine 30 is off, theswitch 132 is opened, enabling the main compressor 40 to be energized.

Note that the diodes D1 and D2 shown in FIG. 2 prevent the correspondingsolenoid valves (46 and 48, respectively) from being opened when thecorresponding on/off switch (122 or 124) is in the off position.

Referring back to FIG. 1, the flow of refrigerant though the airconditioning system is as follows. When the main engine 26 and itscompressor 40 are on and the auxiliary engine 30 and the auxiliarycompressor 120 are off, compressed freon leaves compressor 40 and flowsinto condenser 42 via T-valve 140 and line 142. From the condenser 42,freon flows through refrigerant line 144 into receiver 44. If solenoidvalve 46 is open, freon is released through expansion valve 50 into thecab's air conditioning unit 38. From there, the freon returns throughT-valve 146, refrigerant line 148 and T-valve 149 to the inlet of thecompressor 40.

If solenoid valve 48 is open, freon is released through expansion valve52 into the sleeper's air conditioning unit 39. From there, the freonreturns through T-valve 146 and line 148 to the inlet of the compressor40.

When the auxiliary engine 30 is on, the main engine's compressor 40 isdisabled by switch 132, and thus only the auxiliary compressor 120 canbe used for air conditioning. Compressed freon leaving compressor 120and flows into an auxiliary condenser 156 through line 157. An auxiliaryfan 158 is provided for cooling the freon in the auxiliary condenser156. This fan 158 is automatically turned on if auxiliary compressor 120is on and the pressure in the the outlet of the freon dryer 44 exceeds aspecified pressure level. In an alternate embodiment, the fan 158 ismounted on the shaft of the auxiliary alternator 72 so that the fan 158will run whenever the auxiliary engine is on.

It should be noted that the use of a roof top condenser would be moreexpensive than one located closer to the auxiliary freon compressor 120,and that the increasingly prevalent use of aerodynamic air foils haseliminated the room on the truck's roof for a condenser. Also, it isgenerally impractical to depend on the main condenser 42 for condensingwhen the main engine is off because the main fan 34 cannot run when themain engine is off and there is usually no room near the main engine'sfan 34 for an additional electrically powered fan for cooling the maincondenser 42.

From the condenser 156, freon travels through line 152 to T-valve 140,through the main condenser 42 for additional condensing (even though themain engine fan 34 is off when the main engine 26 is off), and thenthrough substantially the same path used when the main compressor 40 isbeing used. However, the returning freon in line 148 is drawn down line150 back into the compressor 120.

The freon plumbing system in the present invention is designed so thatback flow restriction valves are not needed between the two compressors40 and 120. While gaseous freon can enter the lines leading to acompressor which is not turned on, these lines are evacuated by thecompressor that is on. The outlets of the two compressors need not beprotected with back flow restriction valves because refrigerantcompressors, such as the ones used in automotive air conditioningsystems, already contain a pressure valve at the compressor's outletwhich remains closed when there is no pressure on the valve from insidethe compressor.

In general, the auxiliary system used in the present invention issubstantially more reliable and therefore less expensive to maintainthan the prior art auxiliary systems. The auxiliary system's airconditioning derives its improved reliability from (1) the use ofsimple, well placed connections (the auxiliary equipment interfaces withthe other air conditioning equipment solely at T-valves 140 and 149),and (2) the use of an auxiliary condenser 156 with its own fan 158. Theauxiliary air conditioning system also makes use of the main condenser42 in addition to the auxiliary condenser 156, which significantlyimproves the efficiency of the auxiliary air conditioning system. Theuse of two condensers is accomplished by an unusual parallel connectiondesign, in which both the auxiliary compressor 120 and the auxiliarycondenser 156 are connected in parallel with the primary compressor 40but in series with the primary condenser 42.

The auxiliary air conditioning system also provides a feature not foundin other auxiliary power systems--the ability to run the truck's airconditioner using an auxiliary engine while the primary engine is inoperation. Thus, when the truck is heavily loaded and/or going up longsteep grades, the air conditioning load can be removed from the mainengine without having to forego air condition in the truck's cab.

Another advantage of the present invention is that the flow pattern ofthe combined coolant systems, and the use of the auxiliary engine'swater jacket as the sole heat cogeneration source, provides anintegrated coolant plumbing and cogeneration system which is highlyreliable.

While the present invention has been described with reference to a fewspecific embodiments, the description is illustrative of the inventionand is not to be construed as limiting the invention. Variousmodifications may occur to those skilled in the art without departingfrom the true spirit and scope of the invention as defined by theappended claims.

For instance, in the preferred embodiment there is no special provisionmade for heating the fuel tank because the heat generated by running theauxiliary engine 30 has been found to be sufficient to keep the dieselfuel from gelling. However, in an alternate embodiment for colderenvironments, an electrical heater (such the heater sold under thetrademark HOTLINE by Peterbilt Motors Company) is provided for heatingthe fuel tank 62 to prevent the fuel therein from gelling at lowtemperatures.

What is claimed is:
 1. In a truck or other heavy duty vehicle having acab, a battery, a main engine having an engine block and a water jacket,a radiator and coolant lines coupling the water jacket of the mainengine to the radiator, at least one heating unit and additional coolantlines including an additional outlet coolant line for delivering coolantfluid from the water jacket of the main engine to the heating unit andan additional inlet coolant line for returning coolant fluid from theheating unit to the water jacket of the main engine; an auxiliary powersystem comprising:a secondary engine smaller than and independent ofsaid main engine, said secondary engine having a water jacket with aninlet for coolant fluid and a auxiliary water pump for pumping coolantfluid out of said water jacket of said secondary engine; and auxiliarycoolant lines including an auxiliary coolant outlet line for routingcoolant pumped by said auxiliary water pump into said water jacket ofthe main engine, and an auxiliary coolant inlet line for routing coolantfluid from the water jacket of the main engine into said water jacket ofsaid secondary engine; said auxiliary coolant outlet line being coupledto the additional coolant inlet line, for returning coolant fluid fromthe heating unit to the water jacket of the main engine, with one waycheck valves in said auxiliary coolant outlet line and in the additionalcoolant inlet line to prevent back flow of coolant fluid into theheating unit and into said secondary engine's water jacket. whereby thewaste heat generated by said secondary engine can be used to heat themain engine and the heating unit.
 2. The auxiliary power system setforth in claim 1, whereinthe truck or other heavy duty vehicle has anair conditioning system including a primary compressor, a primarycondenser, at least one air conditioning unit, and refrigerant linesincluding a first refrigerant line coupling the primary compressor tothe primary condenser, an outlet refrigerant line for deliveringrefrigerant from the primary condenser to the air conditioning unit andan inlet refrigerant line for returning refrigerant from the airconditioning unit to the primary compressor; said auxiliary power systemfurther including an auxiliary air conditioning system having: anauxiliary compressor, driven by said secondary engine, having an inletand an outlet; an auxiliary condenser having an inlet coupled to saidoutlet of said auxiliary compressor and an outlet; an auxiliary fan forcooling said auxiliary condenser; and auxiliary refrigerant lines forconnecting said auxiliary compressor and condenser to the airconditioning system in parallel with the primary compressor, includingan auxiliary outlet refrigerant line coupling said auxiliarycompressor's outlet to the first refrigerant line coupling the primarycompressor to the primary condenser, and an auxiliary refrigerant inletline coupling said inlet of said auxiliary compressor to the inletrefrigerant line for returning refrigerant from the air conditioningunit to the primary compressor.
 3. The auxiliary power system set forthin claim 2, said auxiliary air conditioning system further includingelectrical control means for enabling the use of said auxiliarycompressor and disabling the use of said primary compressor when saidauxiliary engine is running;whereby said auxiliary air conditioningsystem can be used to provide cold refrigerant to the air conditioningunit even when the main engine is running. whereby said auxillary airconditioning system can be used to provide cold refrigerant to the airconditioning unit even when the main engine is running.
 4. Theauxilliary power system set forth in claim 2, furhter includinggenerator means driven by said secondary engine for recharging thebattery, and for providing a.c. electrical power to run connentionala.c. electrical accessories.